Modular Vs. Custom Material Handling Equipment: Comparing Manufacturing Lead Times

At BHS, we’ve built our brand as a leading manufacturer of ergonomic material handling and industrial equipment. We operate a 148,000-square-foot facility in St. Louis, Missouri, featuring the latest in CNC machining, robotic welders, and laser technology. 

And since we operate as a manufacturer — rather than simply selling to manufacturers — we understand some processes cannot be simplified with off-the-shelf products. Sometimes, custom material handling equipment is essential, and our engineering team regularly works with businesses to find novel solutions.

When ordering custom material handling equipment, however, manufacturing lead times can be a significant concern. Today, we’ll discuss our approach to custom manufacturing. 

We'll also explain why many of our products feature modular designs to help bridge the gap between custom manufacturing and standard production timelines.

Custom Material Handling Equipment: Factors That Drive Lead Times

Custom manufacturing has a mixed reputation. If you’re building a lean facility, you probably need equipment that accommodates the workflows you’ve created — but to many managers, “custom" means “be ready to wait up to 52 weeks for delivery.”

We solve that problem by addressing the factors that lead to bloated manufacturing lead times:

• Initial Engineering and Modeling: Designing a product requires extensive CAD modeling, structural calculations, and stress testing. BHS utilizes pre-tested baseline configurations, allowing engineers to modify existing structural frames rather than starting from scratch. Crucially, we communicate with the dealer and end user to make sure that we understand the intended process before we suggest features or specifications.
• Custom Tooling and Component Procurement: Unique equipment can mean specialized hydraulic cylinders, non-standard steel profiles, or unique steering components. Those components are often sourced, which introduces a third party (and additional bottlenecks) into manufacturing. BHS eliminates third-party supply chain dependencies by performing fabrication in-house.
• Compliance and Safety Certification: Custom machinery must comply with regulatory benchmarks such as OSHA standards or ASME safety codes for conveyors. Because BHS designs equipment with these regulations built into the foundational architecture, we’re able to avoid lengthy compliance review cycles.

All of this can be summarized in one word: experience. When you’re working with a partner that has a substantial history as a custom equipment manufacturer, lead times aren’t so oppressive. 

Modular Designs Cut Manufacturing Lead Times While Accommodating Unconventional Workflows

Ultimately, custom manufacturing will always take more time than standardized manufacturing. That’s why we’ve built modularity into our product line.

Here are a few examples of designs that allow for flexible implementation — and a fast return on investment. 

Modular Order Picker Platform (OPPM)

The OPPM attaches directly to an order picker forklift to expand the workspace for warehouse operators, allowing them to handle bulkier goods safely. For oversized inventory, opt for the Order Picker Furniture Platform (OPPMF), which has an extended base for furniture order picker trucks.

Modular Order Picker Cart (OPCM)

The OPCM is a towable or pushable industrial cart built to transport pulled stock through warehouse aisles. Operations moving massive or elongated freight can utilize the Order Picker Furniture Cart (OPCMF), a specialized variant featuring an extended footprint to safely accommodate loads up to 96 inches deep.

Modular Storage Rack (SKU: 26301246)

Industrial warehouses use storage racks to hold parts, bins, and cartons. Storage racks aren’t particularly fancy equipment, but they’re certainly essential — and when operations begin to scale, storage limitations can become a big issue.

Work Faster, Safer, and Smarter with BHS

So, do you need custom material handling equipment, or will a modular design provide the same utility (and potentially more flexibility)? 

Our engineers can help you make the right decision for your operation. Whether you need a quick tweak to an existing design or an entirely new solution to a novel problem, we have the knowledge, experience, and infrastructure to deliver equipment within your production schedule.